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for Driveshafts / Industrial Applications Important Product Information and Safety Instructions
Installation
Disassembly Flange bolting Companion flanges Maintenance Maintenance intervals Inspection Lubrication Recommended regreasing intervals Repair Additional information and ordering instructions After-sales service
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Spicer Gelenkwellenbau GmbH
Safety instructions
Our products have been developed and tested according to the latest state-of-the-art engineering.
The characteristic features of the products which are described in our information material or which we specified in writing were subjected to proper and careful inspection. Other features are possible but they are subject to our written confirmation. Knowledge of the various demands on GWBTM products for a particular application lies with the purchaser. The selection of shaft types and the specification of sizes on our part shall in all cases be considered only as a recommendation. Purchaser is required to verify the drawings and documents submitted by GWB based on the data submitted by purchaser. It is the purchasers responsibility to determine the fitness of the product for its intended use. When using, handling, installing, and maintaining driveshafts the following safety instruction must be strictly observed to prevent injury to persons or damage to
Rotating Driveshafts
WARNING
be performed by trained and qualified personnel who are familiar with these instructions, general safety standards, and EC Regulation for machinery, if applicable. The operating data of the driveshafts, such as speed, deflection angles, lengths, etc., must never be exceeded. Do not alter driveshafts in any way without our written consent. If you do so, you may be creating a safety hazard and you are no longer covered by our warranty. The balanced state of a driveshaft must not be altered. An out-of-balance driveshaft may result in uneven running and premature wear of the joints and bearings of the units to which the driveshaft is connected. In extreme cases of imbalance, the driveshaft could break and components could be thrown from the vehicle or machine.
Rotating driveshafts are dangerous. You can snag clothes, gloves skin, hair hands etc, which can cause serious injury or death. Do not work on an exposed drive shaft when it is running and be sure the power source is off. Exposed driveshaft must be guarded. Suitable safety devices (e.g. catch bows, solid safety guards) must be provided to prevent possible serious injury or death, or damage to property from thrown parts in the event of a separated shaft
Other Important Safety Information Installation, assembly and maintenance work should only
WARNING
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Spicer Gelenkwellenbau GmbH
joint range
joint range
Please consider the following precautions: Use strong nylon ropes or lifting belts. When using steel cords, protect the edges. Driveshafts should be transported in a horizontal position (see illustration). For non-horizontal transportation additional precautions
must be taken to prevent the splined parts from separating. Danger of injury! When lifting or putting down the shaft, the moving parts (flange yoke and journal cross) may tilt and lead to injuries. Keep hands away from the joint! Danger of crushed hands!
Avoid bumps and knocks during transport and storage. Do not store or handle the shaft with any stress or load on the spline protection (1) or the seal (2).
Series 587, 687, 688 Use appropriate frames or racks for storage, so that the flange yokes are not loaded.
Series 390, 392, 393 Use chocks or blocks to prevent driveshaft from rolling. Secure shaft against falling over if it is stored in a vertical position. Keep driveshafts in a dry place.
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Spicer Gelenkwellenbau GmbH
Installation/dismantling
Installation
WARNING
See Rotating Shafts warning on Page 3. Important Product Installation Information In order to maintain the properties of the driveshaft as described in the information brochure, they must not be altered from their as delivered state. Driveshafts are elastic and flexural bodies. Their flexural vibration and their critical bending speed must be calculated. The maximum permissible operating speed must be sufficiently below the critical bending speed of the first order. For the smooth running and safety of the shaft the n x value (speed x deflection angle) of the relevant shaft size must not be exceeded. Please contact us.
The faces and the centering diameter of the shaft flanges and companion flanges must be free of dust, grease or paint to guarantee a safe connection. Be careful when handling the driveshaft. Freely moving flange yokes may cause injury. Check position of yokes (1) of the shaft. Observe the arrow markings (2). They must be in alignment. The splines are fitted to one another and must not be exchanged or distorted. Protection caps should be removed from the regreasingand ventilation value before use. Before installation remove the transport retainer device, if present. In case of doubt please contact the supplier.
Check the axial and radial runout as well as the spigot fit of the mounted flanges and the connected units (see Companion flanges on page 12). Do not turn the joints of the driveshafts with assembly levers because this may damage the grease nipples or relief valves. Use nuts and bolts of the prescribed quality (strength) (see Flange bolting on page 7). Only use nuts and bolts in accordance with the suppliers specification. The bolts should be evenly tightened crosswise with a torque wrench (see Flange bolting on page 7).
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Spicer Gelenkwellenbau GmbH
Installation/dismantling
When using driveshafts without length compen- sation, one of the connecting units must be exible in order to be fitted over the flange pilot. Variations in length which may be caused by temperature changes must be allowed for by a suitable connecting bearing. If driveshafts with length compensation are used, the companion flanges must be firmly tted on the shafts of the connected units. For spray-painting the shaft we recommend our paint standards (Please ask for them). Protect rilsan-coated splines (sleeve muff or sleeve yoke) against heat solvents mechanical damage. Visible rilsancoated areas should not be painted after installation in the driveline. Danger of sealing damage! When cleaning driveshafts, do not use aggressive chemical detergents or pressurized water or steam jets because the seals may be damaged and dirt or water may penetrate. Driveshafts can be used in a temperature range between 25C (13F) and +80C (+176F), up to +120C (+248F) but only for limited periods and not on a frequent basis. Please contact us if the operating temperature deviates from these values.
La
Driveshafts that have been stored for more than 6 months must be relubricated before use (see Maintenance). In general we recommend to relubricated the driveshaft after setup in the driveline. For spray-painting the driveshaft, make sure that the sliding range of the seal (length compensation L a) is covered.
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Spicer Gelenkwellenbau GmbH
Installation/dismantling
Disassembly
Before disassembly protect the driveshaft from spline separation. We recommended a bolting set consisting of: Hexagon bolt with short thread similar to DIN 931/10.9 (shaft length greater than flange thickness) Self-locking nut, similar to DIN 980/934-10. The bolts allow fitting a) partially from the joint side, i.e. the recessed diameter c does not prevent the bolt from turning; b) from the companion flange side. We recommend designing the recessed diameter C1 so as locate the bolt head. See tables for insertion of bolts. All bolts must be tightened with the specified torque. The tightening torques Ta given in the table are based on a 90% (80% Hirth-serration) utilization of the elastic limit and apply to slightly oiled bolts. Do not use molycote paste or any other grease on the bolts and nuts. In case of corrosion protected bolts and nuts, please contact us. Max. permissible tolerance of DIN 25202 class B.
CAUTION
You must secure the driveshaft against falling down before pulling it off the companion ange. The ange yoke may tilt, which could cause injury! Observe the directions for transport, storage and installation of driveshafts.
Flange bolting
The flange bolting set can be supplied by GWBTM on request. The bolt lengths given in the tables are only suitable if the dimension 2 x G corresponding to the double the flange thickness G is not exceeded (see data sheets). If longer bolts are used, check whether the bolts can still be inserted from the joint side.
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Installation/dismantling
Series 587/687/688
l 2xG v
mm Nm mm mm mm mm mm
587.50
587.55
d l v s i1 )
c1
Joint flange
Shaft size Flange dia. A Ta c c1 d l v s i1 ) Bolts inserted from joint side Bolts inserted from joint side
687/688.35 150 120 100 110,3 M 12 33 13 19 8 yes 180 190 119 132,5 M 14 40 16 22 8 yes
Shaft size Flange dia. A Ta c c1 d l v s i1 ) Bolts inserted from joint side Bolts inserted from joint side
687/688.40 150 120 100 110,3 M 12 33 13 19 8 yes yes 180 190 119 132,5 M 14 40 16 22 8 yes yes
687/688.45 180 190 119 132,5 M 14 40 16 22 8 yes yes 225 295 158 171 M 16 50 20 24 8 yes
687/688.55 180 295 118 130,5 M 16 50 22 24 10 yes yes 225 295 158 171 M 16 50 20 24 8 yes
687/688.65 180 295 118 130,5 M 16 50 20 24 10 no 225 295 158 171 M 16 50 20 24 8 yes
1)
Ta
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Spicer Gelenkwellenbau GmbH
Installation/dismantling
Series 390
Standard bolting
mm Nm mm mm mm mm mm
l 2 xG v
d
Hexagon bolt: short model similar to DIN 931/10.9
c1
c
Joint flange
Series 587/390
Dowel pin connection
Shaft size Flange dia. A Ta c c12 ) d l ds ls v a s i1 ) Bolts inserted from joint side
mm Nm mm mm mm mm mm mm mm mm
l a a 2xG
Hexagon bolt: short model similar to DIN 931/8.8 Hexagon nut: similar to DIN 980/10 Self-locking Dowel pin: DIN 1481 Joint flange Dowel pin: DIN 7349
ds
60 30 8
c1
30 4 yes
Series 587/190
Super short designs
mm Nm mm mm mm mm mm
l 2 xG v
M 20 65 21
d
Hexagon bolt: short model similar to DIN 931/10.9
c
Joint flange
30 10 yes
c1
35
1) 2)
Ta
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Spicer Gelenkwellenbau GmbH
Installation/dismantling
Series 392/393
Flange connection with face key
l 2xG v
d
Hexagon bolt: short model similar to DIN 931/10.9
c1
c
Joint flange Shaft size Flange dia. A Ta c c1 d l v s i1 )
mm Nm mm mm mm mm mm
1)
Ta
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Installation/dismantling
Series 492/498
2xG
Hexagon bolt: short model similar to DIN 931/10.9 Hexagon nut: similar to DIN 980/934-10 Self-locking
Series 492
Joint flange
mm Nm mm
Series 498/598
mm Nm mm
1)
Ta
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Spicer Gelenkwellenbau GmbH
Installation/dismantling
Companion flanges
In general, driveshafts are connected to the driven units by companion flanges. The accurate running of a driveshaft requires certain tolerances for the axial and radial run-out (see tables). The dimensions of the companion flanges correspond with those of the same size of driveshafts, except for the centring depth FA and the fit CA , the depth of the keyway tA and the width bA . They can be taken from the following tables. For better bolt locking we recommend designing the relief of the companion flange as a bolt head surface and inserting the bolt from the companion flange side. In this case the distance Zmin must be met between the flange and the adjacent housing. If it is not possible to insert the bolts from the companion flange side, we recommend the use of stud bolts.
G X
X = Axial run-out = Radial run-out Y Z min = bolt length (incl. bolt head)
Series 587
Shaft size A
mm mm mm mm mm
587.50
587.55
bA
CA
FA
tA
G X and Y CA h6
FA
Zmin
Series 687/688
mm mm mm mm mm
mm mm mm mm mm
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Spicer Gelenkwellenbau GmbH
Installation/dismantling
Series 390
mm mm mm mm mm
Series 587/190
Super short designs
mm mm mm mm mm
Series 392/393
mm mm mm mm mm mm
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Maintenance
Maintenance intervals
Driveshafts are used in a great variety of industrial plants with very different operating conditions. We recommend inspections at regular intervals and, if possible, to coordinate them with maintenance work on other parts of the equipment. However maintenance work should be carried out once a year at least. Check the flange bolts for tightness and retighten them with the prescribed torque (see Flange bolting on page 7). Backlash inspection. By lifting the joints and the length compensation check the visible or tangible backlash. Check the driveshaft for any unusual noise, vibration or abnormal behaviour and repair the damage, if any. The use of incompatible lubricants or greases can result in driveshaft failure and possible separation of the driveshaft. GWBTM driveshafts are lubricated with grease and ready for installation. For relubrication of driveshafts, use a standard grease according to STD 4006-000. You may use a lithium complex grease ONLY if it meets the following specification : KP2N-20/DIN 51502 accor- ding to DIN 51818. Do not use grease with molycote additives! Original standard GWB grease can be mixed ONLY with lithium complex grease on mineral oil base. Clean the grease nipples before relubricating. Use adequate regreasing devices. For joint relubrication minimal pressure of 15 bar is required. For the length compensation it depends on the design. The regreasing must be continued until fresh grease becomes visible from all four seals. Driveshafts that have been stored for more than 6 months must be regreased before use.
Inspection
WARNING
Excessive looseness can cause imbalance or vibration in the driveshaft assembly. Imbalance or vibration can cause premature component wear, which can eventually result in separation of the shaft resulting in serious injury to persons or damage to property. It is important that you follow the inspection procedures.
Lubrication
WARNING
Lubrication Warnings In adequate lubrication intervals or improper lubrication can cause journal cross burn up, which can lead to separation of the shaft or connecting components from the vehicle or machine, resulting in serious injury or damage to property.
Central lubrication
4 point lubrication
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Spicer Gelenkwellenbau GmbH
Maintenance
When cleaning driveshafts, do not use aggressive chemical detergents or pressurized water or steam jets because the seals may be damaged and dirt or water may penetrate. After a cleaning, the driveshaft must be regreased until the grease escapes out from all four seals. which can result in separation of the driveshaft from the machine or vehicle. The journal cross assemblies may be relubricated via a conical grease nipple (DIN 71412) located in the middle of the cross or at the bottom of the bush. The journal cross assembly has to be replaced before the calculated bearing lifetime is reached. The bearings of the journal cross must be lubricated until the grease passes through from all four seals of the bearings. Driveshafts of the series 498/598 (in special cases also the series 390, 392, 393, 492) must be lubricated via a flat grease nipple according to DIN 3404. The illustrated adapter pipe can be used as adapter between a conical grease nipple at the driveshaft (acc. to DIN 71412) and a flat grease nipple connection at the grease pump (see illustration). Grease and air-relief valves must not be removed or replaced by standard grease nipples. Protection caps should be removed from the grease nipples before operation. Relubricating should be done at the shortest compressed length L z of the shaft.
WARNING
Excessive looseness across the ends of journal cross bearing assemblies can cause imbalance or vibration in the driveshaft assembly. Imbalance or vibration can cause component wear,
Length compensation
Order No.: 1 000 00 86 05 006 (90 mm length) 1 000 00 86 05 025 (300 mm length)
The length compensation of the series 390, 392, 393, 492, 190 and 587 as well as special designs of the series 687/688 is lubricated via a combined grease and air-relief valve with a conical grease nipple according to DIN 71412 (no self-locking grease nipple). The length compensation of the series 498/598 is lubricated via a flat grease nipple according to DIN 3404.
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Spicer Gelenkwellenbau GmbH
Repair
Safety Information Regarding Repairs For safety reasons driveshafts should only be repaired by GWBTM or by GWB -approved repair shops. The repair of driveshafts is performed in a professional manner by our driveshaft service experts. The shafts are overhauled using original spare parts. The repair of driveshafts by the user should only be made in emergency cases and only for such equipment where the operating speed of the shaft does not exceed 500 rpm. If the speed exceeds 500 rpm, the driveshaft must be rebalanced. If journal cross assemblies are to be replaced, you should also replace the bearing cap screws of shafts of the series with split yokes. Observe our installation and repair instructions. Improper repairs can lead to driveshaft failures that can cause serious injury or damage to property. Please contact us if you have questions or need additional information.
Danas environmental protection s environmental protection management policy An important feature of Danas environmental protection management policy is dedication to product responsibility. Because of this commitment, the effect of driveshafts on the environment is given considerable attention. GWB driveshafts are lubricated with lead-free grease, their paint finishes are low in solvents and free of heavy metals, and they are easy to maintain. After use, they can be introduced into the recycling process.
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Specic applications
Driveshafts in railway transmissions The selection of driveshafts in the secondary system of railway vehicles must be based on the maximum torque that can be
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Greece Sokrates Mechanics GmbH 205, Piraeus Str. GR-11853 Athens Phone: 00 30-210-34 71 910 Fax: 00 30-210-34 14 554 E-mail: sokrates@enternet.gr
Netherlands GKN Service Benelux BV Haarlemmerstraatweg 155-159 NL-1165 MK Halfweg Phone: 00 31-20-40 70 207 Fax: 00 31-20-40 70 217 Norway
South Africa Driveline Technologies (Pty) Ltd. CNR. Derrick & Newton Roads Spartan, Kempton Park P.O. Box 2649 Kempton Park 1620 Phone: 00 27-11-929-56 00 Fax: 00 27-11-394-78 46 E-mail: richard@driveline.co.za USA, Canada Dana Spicer Service Parts P.O. Box 321 Toledo, OH 43697-0321 Phone: 001-800-621-80 84 Fax: 001-800-332-61 24 E-mail: tom.deHaven@dana.com
Hellas Cardan GmbH Strofi Oreokastrou GR-56430 Thessaloniki Phone: 00 30-23 10-682 702 Fax: 00 30-23 10-692 972 E-mail: hecardan@otenet.gr
GKN Service Scandinavia AB Karihaugveien 102 N-1086 Oslo Phone: 00 47-23 286 810 Fax: 00 47-23 286 819 Russia-Ukraine
Great Britain GKN Driveline Service Ltd. Higher Woodcroft Leek, GB-Staffordshire, ST13 5QF Phone: 00 44-15 38-384 278 Fax: 00 44-15 38-371 265 India Dana India Private Limited Survey No. 278, Raisoni Industrial Park, Phase II, Hinjewadi, Village-Mann, Tal. Mulshi, Pune -411 057 (INDIA) Phone: 00 91-20-30436255 E-mail: sgwb.india@dana.com Italy Uni-Cardan Italia S.p.A. Via G. Ferraris, 125 / C I-20021 Ospiate di Bollate (MI) Phone: 00 39-02-383 381 Fax: 00 39-02-33 010 30 Japan Nakamura Jico Co. Ltd. 10-10, Tsukiji, 3-chome Chuo-Ku, Tokyo Phone: 00 81-3-35 43-97 72 Fax: 00 81-3-35 43-97 79
APA-KANDT GmbH Weidestr. 122a D-22083 Hamburg Phone: 00 49-40-48 061 438 Fax: 00 49-40-480 614 938 E-mail: office@apa-kandt.de Web: www.apa-kandt.de Sweden GKN Service Scandinavia AB Alfred Nobels All 110 SE-14648 Tullinge Phone: 00 46-86 039 700 Fax: 00 46-86 039 702 Switzerland GKN Service International GmbH Althardstrae 141 CH-8105 Regensdorf Phone: 00 41-44-871-60 70 Fax: 00 41-44-871-60 80 Spain Gelenk Industrial S.A. Balmes, 152 E-08008 Barcelona Phone: 00 349-3-23 74 245 Fax: 00 349-3-23 72 580 E-mail: javier.montoya@gelenkindustrial.com
Copyright by Spicer Gelenkwellenbau GmbH All rights reserved. Any reproduction of this publication or parts thereof is subject to the explicit authorization of the copyright-holder. This catalogue supersedes all former editions. We reserve the right to make alterations. Release 03/2012
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Trains
Industrial plants
Ships
Spicer Gelenkwellenbau GmbH Westendhof 5-9 45143 Essen / Germany Phone: 00 49 (0) 201 - 81 24-0 Fax: 00 49 (0) 201 - 81 24-652 www.gwbdriveshaft.com www.dana.com
APPLICATION POLICY Capacity ratings, features, and specifications vary depending upon the model and type of service. Application approvals must be obtained from Dana. We reserve the right to change or modify our product specifications, configurations, or dimensions at any time without notice.
Spicer Gelenkwellenbau GmbH